Self-contained breathing system

ABSTRACT

A breathing apparatus is operable in self-contained and filtered modes of operation. In the self-contained mode of operation, a breathable gas is delivered to a user from a self-contained source of breathing gas. In a second, filtered mode of operation, a suction source draws ambient air through a filter removing contaminants and delivers filtered ambient air to the user. A method of delivering air to a subject is also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority as a continuation application under 35U.S.C. § 120 to U.S. patent application Ser. No. 13/371,744, filed Feb.13, 2012, now U.S. Pat. No. 8,950,401 which claims priority as acontinuation application under 35 U.S.C. § 120 to U.S. patentapplication Ser. No. 12/688,676, filed Jan. 15, 2010, now U.S. Pat. No.8,113,198, which claims priority as a continuation application under 35U.S.C. § 120 to U.S. patent application Ser. No. 10/924,281, filed Aug.23, 2004, now U.S. Pat. No. 7,647,927, which claims the benefit under 35U.S.C. § 119(e) of U.S. provisional application Ser. No. 60/497,206filed Aug. 22, 2003, and U.S. provisional application Ser. No.60/497,215 filed Aug. 23, 2003. Each of the aforementioned applicationsis incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a breathing system and, moreparticularly, a dual-purpose, self-contained breathing system in whichthe air source is switchable between self-contained air supply andfiltered ambient air, as required by the operator. The system findsutility in connection with all manner of hazardous or contaminatedenvironments in which a self-contained breathing apparatus (SCBA) isrequired, including, chemical, biological, and radiologicalenvironments, burning buildings, and so forth. The system allows theuser to switch between a self-contained air supply and filtered ambientair without the need to switch hoses, thereby reducing potentialexposure to contaminants in a hazardous, contaminated, or toxicenvironment.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take form in various components and arrangements ofcomponents, and in various steps and arrangements of steps. The drawingsare only for purposes of illustrating preferred embodiments and are notto be construed as limiting the invention.

FIG. 1 is a front elevational view of an exemplary breathing apparatusaccording to the present invention.

FIG. 2 is a rear elevational view of the breathing apparatus shown inFIG. 1.

FIG. 3 is an exemplary embodiment of a breathing apparatus according tothe present invention adapted to be worn by a user.

FIG. 4 is a front elevational view of the breathing apparatus shown inFIG. 1 with the housing cover removed.

FIG. 5 is a top plan view of the breathing apparatus shown in FIG. 1.

FIG. 6 is a bottom plan view of the breathing apparatus shown in FIG. 1.

FIG. 7 is a side elevational view of the breathing apparatus with thetanks removed.

FIGS. 8-10 are side sectional views illustrating the flow of air throughthe breathing apparatus.

FIG. 11 depicts an exemplary, optional prefilter assembly.

FIG. 12 is an exploded view of the prefilter assembly shown in FIG. 11.

FIG. 13 illustrates an exemplary breathing hose according to a preferredembodiment having a vibrator alarm and purge valve.

FIG. 14 illustrates the purge valve on the mask connector end of thebreathing hose shown in FIG. 13.

FIG. 15 is a schematic functional block diagram of a breathing systemaccording to an exemplary embodiment of the present invention.

FIG. 16 illustrates the modular nature of the system and some exemplarymodules which may be attached in place of one or both of the breathinggas cylinders to expand the functionality of the system.

FIGS. 17 and 18 are assembled and exploded views, respectively, of aone-way check valve for attachment to a port of the user's face mask.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawing figures, wherein the showings are forpurposes of illustrating preferred embodiments of the invention only andnot for limiting the same, FIGS. 1-10 illustrate a breathing apparatus110 including a main body or housing section 112, (also sometimesreferred to herein as a chassis), a base manifold section 114, one ormore self-contained air supply tanks 116, and a breathing hose 118. Thehose 118 includes a first end 120 which may be attached to an outletport 122 on the housing 112. A second end 124 may be attached to aninlet port 129 of a face mask 126 worn by a user 128 for delivery ofbreathable air. The mask assembly 126 may be of a type commonly used inchemical, biological, radiological, or other hazardous environments.

A plurality of fasteners such as connecting pins 133 or other fastenersmay be provided on the exterior of the housing 112 to secure the unit110 to a user wearable garment 131, such as a ballistic vest, emergencyditch system, or the like (see FIG. 3).

In operation, the breathing device 110 is switchable between a first,pressurized air mode in which air from the pressurized tanks 116 isdelivered to the user 128 via the air hose 118 and a second, filtrationmode in which ambient air is filtered via a filtration unit (asdescribed below) and is likewise delivered to the user 128 via the hose118. In this manner the operator 128 has the ability to readily selectthe desired mode of operation, namely, a SCBA mode in which air isdelivered from an attached cylinder 116 and powered air-purifyingrespirator (PAPR) mode of operation in which filtered ambient air isdrawn with blower assistance through one or more air filters orpurifiers and delivered to the user. The facile switching between theself-contained air supply 116 and filtered air is particularlyadvantageous, for example, in the event that the self-contained airsupply 116 becomes exhausted or malfunctions, when it is desired toconserve the self-contained air supply, and so forth. Likewise, a useroperating on filtered air may readily switch to the self-contained airsupply, for example, in low oxygen conditions or when the ambient aircontains dangerous levels of a non-filterable constituent, e.g., as maybe detected employing an optional air sampler module, as described infurther detail below.

The main chassis 112 defines an internal cavity or compartment 113, andmay be manufactured of plastic, preferably chemically hardened plastic,composite materials, aluminum or other metal and alloys thereof, or thelike. The main chassis 112 provides for mounting of externally mountedcomponents thereon and the internal cavity 113 contains internalcomponents, such as a power supply 218, a circuit board 214 andassociated circuitry, blower 208, internal filter 222, and otherinterior components, for operation of the apparatus 110.

In the depicted embodiment, the cavity 113 also serves as the mainbreathing reservoir. As best seen in FIG. 8, the breathing reservoir 113is in flow communication with the breathing hose 118. The housing 112and all connectors and access ports thereon are sealed against entry ofexternal environmental contamination, thereby allowing the unit to beemployed underwater or in otherwise wet or damp conditions. Thebreathing gas (either gas from tank 116 or purified ambient air) isallowed to fill the chamber 113 and breathing bag 118 to provideadditional “next breath” capability and the positive pressure within thebreathing chamber 113, in turn, provides additional resistance againstingress of moisture or other external contaminants. However, it will berecognized that alternative embodiments wherein the flow is confined toa conduit or more limited passageway within the chassis 112 are alsocontemplated.

The circuit board 214 may include a microprocessor, microcontroller, orother logic device 217, which is coupled via an electrical and/or databus 219 to various system components, whereby various system componentsand parameters may be monitored and/or controlled (see FIG. 15). Aprogramming port 221, such as a serial or parallel data interface port,may be provided on the chassis 112 for programming, updating, or testingthe processing circuitry 217 (including an associated memory thereof)without the need to open the unit.

A removable housing cover plate or shell 115 encloses the internalcomponents within the chassis housing 112 and is provided with anenvironmental seal or gasket to prevent air leakage out of the chassisand to prevent entry of moisture, debris, or environmental contaminationtherein. In a preferred embodiment, a cover plate is fastened to thefirst shell portion via a plurality of fasteners 117, such as threadedconnectors, spaced about the periphery of the opening.

In the self-contained or pressurized mode of operation, breathing gas,typically air or oxygen, is stored under pressure in the one or moretanks or cylinders 116 that can be removably mounted to the housingsection 112. The gas storage tanks 116 may be of any type suitable forsupplying a breathing gas. The housing section may be adapted toaccommodate tanks 116 of various, interchangeable sizes. For example, itmay be desirable to select a tank size commensurate with the scope of anoperation or mission, to employ smaller tanks in order to reduce theweight of the system, etc. Although the breathing gas will be describedprimarily in reference to compressed air for ease of exposition, it willbe recognized that other suitable breathing gasses may be used as well.For example, in certain embodiments, one tank may contain compressed airwhile the other tank may contain oxygen. In this example, the tankcontaining oxygen would be designed to prevent oxygen flow into thesystem, the oxygen being used for an accessory function such as for usewith a torch cutting 1117 attachment.

In another preferred aspect, the tank 116 is suitable for high-pressureair/gas storage (e.g., up to about 9,500 PSI, or higher), and may be analuminum-lined, composite (e.g., carbon fiber composite) wrappedhigh-pressure storage tank.

A modular system may be provided wherein one or more modules forexpanding the functionality of the system may be attached to the chassis112. Since the apparatus 110 may be operated with one or two tanks 116,or, in filtered mode, with no tanks 116, one or more special purposemodules may be provided which are interchangeable with one of thebreathing gas cylinders 116.

In one embodiment, a cutting torch module 1117 is contemplated. Thecutting torch module may be of a type employing a burning metal, such asmagnesium, a source of oxygen or other oxidizing gas, and a feed linefor delivering the oxidizing gas to the surface of the material to becut. The oxidizing gas is contained in a cylinder adapted to replace oneof the breathing gas tanks 116.

In another embodiment, a heating and/or cooling module 119 iscontemplated, wherein a circulating source of heating and/or coolingfluid, comprising a pump and a cooling source, heating source, or both,are provided in a module, e.g., a generally cylindrical module, adaptedto mount in place of one of the breathing gas tanks 116. Theheating/cooling module is adapted for use in connection with atube-lined garment through which the fluid is circulated to effect heatexchange with the user's body and, preferably, may be electricallycoupled to the power supply of the apparatus 110.

In still another embodiment, a hydration module may be provided,including a container adapted to be exchanged with a breathing gas tank116 for supplying water or other suitable fluid to the user 128. Also,an alternatively sized cylinder 116′ may be used in place of thecylinder 116.

The base manifold section 114 of the main system body 112 provides aplatform for mounting the tanks 116. The base portion 114 includes achannel or opening 130. Likewise, the cylinder 116 includes a connectionassembly 132 having a connection foot 134 adapted to be removablyreceived in the opening 130. The connection foot is of complimentarysize and shape (e.g., dovetail, tenon, or other geometricalconfiguration) with respect to the opening 130.

A fastener for removably retaining the tank 116 on the base section 114,such as a locking pin engaging aligned receiving holes on the baseportion 114 and the connection assembly 132, or the like, may beemployed. As shown in the illustrated embodiment, a locking pin 152passing through a selected receiving hole 154 or 156 (e.g., depending onthe size of the tank 116 employed) may be used to secure the cylinderfoot 134 within the opening 130 and to prevent inadvertent ejection ofthe cylinder 116. The manifold connection assembly 132 may also includea pressure gauge 148 and a cylinder valve 150, e.g., a manually operablevalve. In the depicted embodiment, the pressure gauges 148 face outwardfrom the operator and may be viewed from the side of the device. Thecylinder valves allow the operator to open and close the air flow fromthe cylinders 116 to an inlet 139 of manifold 140.

In the depicted embodiment, the connection assembly 132 may be adaptedfor either left-side or right-side mounting of the tank 116. A blow-outdisk assembly 136 may be provided to relieve pressure in the event thatcylinder pressure exceeds some prespecified value according to the tankcapacity. In the event of excessive pressure, the burst disk willrupture. A pressure release cap 137 may be provided to retain the diskwhile pressure is released through the cap. The burst assembly 136 mayinclude a blowout disk, O-ring and safety cap, providing the mainpressure relief for the cylinders 116. When the disk blows, it opens anair escape path, allowing air to pass through the aerated cap 137. Thisprevents accidental damage to equipment and operator. In the depictedpreferred embodiment, the burst assembly 136 faces away from thedirection of an operator donning the apparatus 110.

The connection assembly 132 additionally includes a manifold connector138 for providing an airflow connection to a manifold inlet 139 on thebase portion 114. The connector 138 is preferably a threaded connectorwhich is removably connected via complimentary threads on the inlet 139.A sealing ring or gasket, e.g., formed of a material such as a teflon orother sealing material, is preferably provided to provide a sealingengagement between the connector 138 and the inlet 140. The connectors138 may include holes 141 or other features which provide for engaging atool or key to provide leverage when rotating the connectors to ensure atight fit.

The manifold connection assembly 132 additionally includes a fastenerfor securing the air cylinder 116 to the main body portion 112. Theillustrated embodiment includes a retaining band 142 and one or moreretaining nuts 144, e.g., which may be secured to the main body portion112 to provide stabilization of the air cylinders on the main chassis. Ascrew-tight fastener 146 is provided for tightening of the band 142.

A retractable stand 158 may also be provided. In the illustratedembodiment, the retractable stand 158 pivots about a pivot pin 160. Asbest seen in FIG. 6, the stand 158 rotates between a first, retractedposition (see FIG. 1) and a second, extended position (FIG. 6) forstanding the unit 110 upright, e.g., for service or maintenance. In theillustrated embodiment, a notch 162 is provided in the base portion 114for receiving the stand 158 when fully retracted. The stand is removablyretained in the notch 162 by a captured spring 164. A handle or strap166 is provided on an upper portion of the housing section 112 forcarrying the unit 110 when it is not being worn. A hardened plasticstorage case, which may include a foam lining, may be provided forstorage of the unit 110 and its components when not in use.

Switching between the pressurized and filtration modes of operation isaccomplished by a port valve for selectively receiving pressurized airor filtered ambient air. The port valve is controlled by a snorkelassembly 168 including a snorkel cap 170, an ambient air inlet 172, anoptional prefilter 174, and a snorkel tube 176. The snorkel cap 170 ismovable between a first, closed position (see FIG. 9) wherein the inlet172 is closed to ambient air 178, and a second, open position (see FIG.10) wherein the inlet may receive ambient air.

An exemplary optional prefilter assembly 174 is shown in FIGS. 11 and12. The prefilter assembly 174 includes a filter cap 182 and a filterhousing 188, which houses a pre-filter filtration medium 186. Thepre-filter medium 186 may be, for example, a polymeric material, such aspolypropylene, polytetrafluoroethylene, or the like, and may be formedof a mesh material. In a preferred embodiment, the pre-filter material186 is formed of a monofilament polypropylene mesh material. In apreferred embodiment, the prefilter 174 filters particles which are 10microns in size or larger. The filter cap 182 and filter housing 188include perforations 184 and 190, respectively, for passage of ambientair therethrough.

The optional prefilter advantageously provides filtering of ambient airprior to entry into the system, preventing dust buildup in the filtercompartment chamber. The filter may be housed within a hardened housing182 that has openings 184 formed therein and a connector, such as athreaded connector 189. This hardened cover protects the snorkelassembly from entanglement and other damage. A source of gas may beprovided to unclog or remove dust and debris from the externally facingsurface of the prefilter and/or main filter. That is, air or other gasmay be passed air from an internal source outwardly therethrough, in thedirection opposite to the air flow in normal, breathing operation. Thesource of gas may be, for example, the air contained in the breathingtanks 116, e.g., delivered from the first stage gas pressure regulator244, via the connector 238, and so forth. Alternatively, or in addition,the source of the gas used for cleaning the filter may be a speciallyprovided source, such as a carbon dioxide tank or cartridge. A valve andactuating means such as a manual valve actuator may be provided to allowthe filter cleaning gas to be forced outwardly through the filter inquick bursts. Additionally, or alternatively, a burst of air may beforced outwardly through the prefilter each time the snorkel is raisedprior to use. The burst of air may be actuated, for example, via aswitch or other snorkel position indicator 175 (see FIG. 15) located onthe prefilter cap or elsewhere on the prefilter assembly. The switch maybe, for example, an electrical switch or position indicator providing asignal for actuating or controlling an electrically operated air valve,a mechanical air valve actuator, and so forth. The burst of air may beactuated under preprogrammed control whenever the snorkel is moved fromclosed to open position.

In the depicted preferred embodiment, the housing 182 is adapted toaccommodate an additional, external filter 181. The filter comprises amesh or woven filtration medium which covers the cap 182 andperforations 184 and is secured at the base 183 with an annular fastener185 such as a tie, band or the like. Advantageously, a groove 187 isprovided to prevent the flow of air around the external filter 181 andto prevent dislodging of the annular fastener 185. In a preferredembodiment the external snorkel filter 181 is formed of a woven nylonmaterial of a type used for nylon hosiery. The external filter 181 isreadily cleaned or replaced and prolongs the life of the innerfiltration medium 186.

The snorkel assembly may be moved between the open and closed positionsby manually lifting or depressing the snorkel cap 170, respectively.Alternatively, a control module 192 may be provided for switchingbetween pressurized tank air and filtered air. The control moduleincludes a housing 194, a button or key 196 for toggling between thefiltered and self-contained air sources, a visual indication or display198 indicating the air source currently selected and a display 200, suchas a liquid crystal display (LCD), light emitting diode (LED) display,or the like, indicating the system pressure or pressure remaining in thetank 116. The control module 192 may also control and/or display blowermotor speed, cylinder pressures, battery life, friend/foe identificationsystem, or the like. It may also contain a backlight for the display200.

It will be recognized that alternative configurations of the controlmodule 192 may also be employed. For example, a single display combiningthe pressure display 200 and the source selection indicia 198 may beused.

An electrical cable 202 electrically couples the module 192 to theelectrical system of the apparatus 110, e.g., via an electricalconnector 204 which may be connected to a mating electrical connector206 on the housing 112. The connectors 204 and 206 may include matingthreaded connector housing members. The button 196 also serves toactivate an internal suction source 208, such as a fan or blower (theterms “fan” and “blower” will be used interchangeably herein unlessspecifically stated otherwise) via the electrical cable 202 whenfiltered ambient air is selected as the air source.

Optionally, programming or control circuitry in the apparatus 110 may beprovided to automatically switch from pressurized mode to filtered modewhen the remaining air supply in the tank 116 is exhausted orsubstantially exhausted, or the tank pressure or system pressureotherwise falls below preselected value.

The main housing portion 112 further includes a battery compartment 210containing a power supply 218, such as one or more batteries or batterypacks for providing power to the electrical components of the apparatus110. In some cases, the power supply 218 may also electrically coupledto provide power to one or more electrically operated, externallymounted modules which may be provided to expand the functionality of theapparatus 110. In the depicted embodiment, a removable cover 212 isprovided on an exterior surface of the housing portion 112, and ispreferably sealed against moisture and other external contaminants,e.g., via an O-ring or other sealing ring or gasket. In the illustratedembodiment, a power selection switch 216 is provided on the batterycompartment cover 212 for turning the device 110 on and off. When turnedon, the power system powers the blower, control module, and any otherelectrical components, such as a pressure sensing and alert system (asdescribed in greater detail below), or other optional chassis-mountedcomponents.

In a preferred embodiment, the compartment 210 accommodates eight 3-voltbatteries, such as lithium ion batteries, in which four chambers eachaccommodating two batteries in series configuration and the fourchambers being electrically connected in parallel. Thus, in thispreferred embodiment, the compartment thus accommodates up to four setsof two batteries to provide a 6-volt output. In this manner, the unitmay be operated on fewer than eight batteries for noncriticalapplications, such as training, testing, or servicing of the apparatus,whereas a full complement of eight batteries is recommended for a fullmission. It will be recognized that other battery and batterycompartment configurations, including removable and/or rechargeablebatteries or battery packs, and the like can be used. Likewise, anexternal electrical connector may also be provided for recharging theinternal batteries when a rechargeable power source is used.

A main filter compartment 220 in the chassis 112 houses a main filter222, such as a radiological, biological, or chemical filter. The filter222 includes an inlet 224 for receiving ambient air 178, which may beprefiltered in the case wherein an optional prefilter is employed. Thefilter 222 further includes an outlet 226 for filtered air.

The filter 222 is preferably secured within the compartment 220 via aconnector 228. Preferably the connector 228 is a threaded connector,most preferably a standard NATO 55-millimeter male threaded connectorwhich removably rotatably engages a complimentary female threadedconnector in the compartment 220. An O-ring or other sealing ring orgasket 229 is provided in the base of the threaded connector to preventflow around the filter canister 222. A filter compartment cover 230seals against air leakage and against the entry of moisture or othercontaminants. The filter cover may be formed of aluminum and includethreads which rotatably and removably engage complimentary threadsformed in the filter compartment 220. An O-ring 231 or other sealingring, gasket, or the like, may be provided to provide an environmentalseal. In a preferred embodiment, an extension ring or sleeve may beprovided between the compartment 220 and the cover 230 to extend thecompartment and accommodate additional filter sizes. Because the filtercompartment 220 is not exposed to air when the snorkel is down, theapparatus 110 allows for extended storage of the filter 222 withoutdegradation due to exposure to air. In this manner, the filter may beinstalled in advance of use, thereby improving response time as comparedto a conventional PAPR unit in which the filters must remain in aseparate sealed container or packaging and installed just prior to use.Likewise, the apparatus 110 may be used in SCBA mode in rain or otherwet conditions, including under water, without affecting the filter.

An intermediate-pressure “buddy” connector 238 may be provided on anexterior surface of the chassis 112 and is preferably of a quickconnect/disconnect type as generally know in the art. The connector 238is in flow communication with the first stage regulator 244 via conduit243 and provides an external (e.g., about 80 psi) connection forattaching various second stage regulators. In this manner, use of theair supply of the breathing system 110 may be shared by attaching anexternal breathing device or mask incorporating a second stageregulator. Alternatively, the intermediate pressure connection port 238may be used to operate pneumatically operated tools and devices. Aconnection cap 239 may be provided to prevent moisture and debris fromcontaminating the connection 238.

A high-pressure charging valve 240 may be provided on an exteriorsurface of the chassis 112 for connection with an external chargingdevice for charging the tanks 116 with air/breathing gas. The valve 240is in flow communication with the manifold 140 via conduit 245. Aprotective cap 241 may be provided to prevent moisture and debris fromcontaminating the connector 240. The connector 240 is preferably of aquick connect/disconnect type as generally known in the art. In additionto charging the tanks 116, the high pressure port 240 may also be usedto couple the apparatus 110 to an external source of breathing gas. Theexternal source may be, for example, an additional tank or may be astationary source of breathing gas, e.g., a compressor or a pressurizedvessel, in which case the user is tethered to the stationary breathinggas supply by a line connecting the connector port 240 and an outlet ofthe source.

In operation, one or both of the cylinder valves 150 may be opened andthe connector 240 connected to a source of breathing gas and charged toa desired pressure. The cylinder valves 150 may then be closed and thecharging source disconnected from the connector 240.

The chassis 112 additionally includes at least one connection port (122,123) for connection to the breathing hose 118. In the depictedembodiment, left-side and right-side connection ports 122 and 123,respectively, are provided to accommodate both left-handed andright-handed operation. For example, the left port 122 provides aleft-side connection for the breathing hose 118, thereby keeping theright side free for a right-handed marksman. Likewise, the right port123 provides a right-side connection for the breathing hose 118, therebykeeping the left side free for a left-handed marksman.

The breathing hose 118 is attached to a selected one of the ports 122and 123 via the hose connecting end 120. A blanking plug or cap 242seals the other one of the ports 122 and 123 to prevent contaminantentry via the unused port. The connection between the ports (122, 123)and the hose connector end 120 or the plug 242 are preferably of a quickconnect/disconnect type and preferably incorporates an O-ring or othersealing ring or gasket to seal against entry of moisture or otherexternal contaminants. The port readily accepts the quick-connect end ofthe breathing hose, and contains a quick-connect electrical appliancefor powering the vibrator unit within the mask adaptor and a gas linefor coupling to the purge valve line 266 (see FIG. 13) in breathing hose118.

In the pressurized mode of operation, the snorkel is in the down orclosed position and one or both of the valves 150 are opened. Air exitsthe cylinders 116 via the respective open valve 150 and passes thepressure gauge 148 and pressure relief assembly and enters the mainmanifold 140 of the housing 112.

The air then passes to a first stage regulator 244, which may be of atype commonly used for pressurized or self-contained breathingapparatuses. The first stage regulator 244 may be of a type, forexample, including a diaphragm which is acted upon by fluid pressure toreduce the pressure of the air passing through the regulator. Thepressure is reduced to a first reduced pressure level, which ispreferably about 80-100 psi. The first stage regulator 244 may alsoinclude a relief valve for pressure relief for the regulator when thepressure of the gas exiting the first stage regulator exceeds somepre-selected or pre-determined value, e.g., about 100-120 psi. Therelief valve may be, for example, of a spring-loaded type which relievespressure at a first threshold value and returns at a second thresholdlevel. For example, the relief valve may relieve at a pressure of about100-120 psi and return at a pressure of about 90-110 psi.

Air then passes from the first stage regulator 244 to a regulatedpressure junction 246 and on to a second stage regulator 248 where it isfurther reduced for breathing. In addition to supplying the breathinggas to the second stage regulator 248, the regulated pressure junction246 may also divert gas at about 80 PSI to additional locations withinthe breathing apparatus 110 for various pressure actuated services asdescribed herein, such as an optional purge valve, a gas driven pistonfor selecting between the self-contained and filtered modes ofoperation, air for prefilter cleaning. The second stage regulator 248reduces the air pressure to a level suitable for safe breathing (e.g.,about 1-5 psi). Air passing through the second stage regulator 248 isthen delivered to the operator via the compartment 113 and the hose 118to the interior of the mask assembly 126.

In the depicted preferred embodiment, air passes from the second stageregulator 248 through a conduit 250 to an internal orifice 252 then intothe chassis 112, the inside of which is a compartment defining aninternal breathing air reservoir or chamber 113.

An outlet valve 127 on the mask 126 includes a one-way check valveplaced over the existing breathing exhaust port on the face mask throughwhich gas in the mask 126 may exit in the event the pressure in the maskis above some threshold level. The pressure of the gas in the mask,either from the suction source 208 or from the second stage gas pressureregulator 248, is greater than the ambient, atmospheric pressure,thereby resisting entry of external air, even in the event that the sealbetween the user's face and the mask is momentarily broken, e.g., due touser movement. This positive pressure in the mask also assists inpreventing fogging of the interior of the mask.

The outlet valve 127 is shown in FIGS. 17 and 18. The device is placedover the existing breathing exhaust port on a protective mask. It may befastened in place via an adapter housing 133 with adhesive and amechanical hook system 135 which mates with the adapter port on themask. The device includes a spring-loaded outlet valve 143 regulatesexhaust air flow by use of a calibrated spring that provides compressionon the purge valve. The purge valve is retained via an annular retainingcap 145. The valve 143 may be made of various materials includingpolymers and may be coated with HSF, PTFE, or the like. The outlet valve127 maintains regulated positive pressure in the mask thus eliminatingthe free flow of air, or other breathable gas, from the mask's standardexhaust port. The outlet valve 127 is also designed so that it releasesgas from inside the mask before the pressure inside the mask is raisedto the point where gas is exhausted between the mask's sealing surfacesand the wearer's skin. Breaking the seal between the mask's sealingsurface and the wearer is not a desired occurrence because of theprobability of introducing a contaminant into the mask thusincapacitating the wearer. In the event that the mask seal isinadvertently breached the positive pressure created by the mask adapter127 eliminates the possibility of a contaminant entering the mask.

Preferably, the second stage regulator 248 includes a diaphragmresponsive to pressure differentials to provide demand breathing gas toa user in communication with the regulator 248. Air in the chassis 113is held in place until demand is placed on the system, i.e., when theoperator inhales. Air then passes through the outlet (122, 123) of theinternal chamber 113 through the hose 118 connecting the main systembody to the mask.

In certain embodiments, the exterior facing surface of the diaphragm maybe coated or treated to protect against corrosion or degradation whenexposed to chemical or biological agents. In one embodiment, aprotective polymer layer is bonded to or deposited on the outwardsurface of the diaphragm. The polymer layer is preferably a polymerhaving a high degree of chemical resistance such as afluorine-containing polymer and, more preferably,polytetrafluoroethylene (PTFE). The polymer layer may be applied in theform of a sheet or film bonded to the diaphragm or in the form of asolution or dispersion, e.g., liquid, paste, cream, gel, or similarformulation, containing monomers and/or polymer precursors, which aresubsequently cured in place to form the protective layer. A removablecover or port 249, secured by a retaining ring or clamp 247 may beprovided to allow access to or servicing of the second stage regulatordiaphragm.

Other components may also be provided with a protective polymer layer toprevent degradation in harsh chemical and/or biological environments asdescribed above and in one embodiment, the entire assembled unit may becoated with a solution or dispersion of monomers and/or polymerprecursors and cured to protective polymer film, preferably of PTFE,over the entire unit prior to use.

Any known type of breathing hose may be employed as the breathing hose118. However, in a preferred aspect, an inhalation hose assemblyproviding next breath capability is provided. In the depicted exemplaryembodiment shown in FIGS. 13 and 14, the illustrated inhalation hoseassembly 118 includes an inner perforated hose 254 having perforations258 along its length, which is contained within a flexible outer bag260. The outer bag inflates to provide a ready volume of air, e.g., upto two liters of air, providing the operator with a “next breath”capability. The additional volume of air contained in the bag 260 isespecially advantageous in that it eliminates the need for employingmultiple filters and blowers in that sufficient volume of breathing gasis delivered to the user, even under high exertion. The “next breath”capability also provides positive pressure (e.g., about 5 psi) in theuser mask 126. The inner hose 254 also provided a structuralstrengthening between the ends of the hose 118 and serves to house theelectrical cable 270 and purge line 266.

The bag 260 may be formed of a woven polymeric material, such as a highstrength fluoropolymer (HSF), polytetrafluoroethylene (e.g., Teflon),etc. Optionally, an inner lining 262 may also be disposed between theperforated hose and the outer bag. The inner lining or bag 262 may beformed of a natural or synthetic polymer material, such as butyl rubberor the like. The optional inner lining 262 functions as a bladder andprovides an extra level of protection against external contaminant entryinto the air stream, e.g., in the event the outer bag 260 is cut orabraded. A fire-retardant layer or coating may also be provided orapplied to the bag 260.

The inhalation hose assembly 118 is connected to the chassis portion 112via the connector 120 and to the user mask 126 via a connector at 124 atthe proximal end of the hose 118. The connectors 120 and 124, which maybe the same or different, may be, for example, threaded connectors,quick-connect type connectors (e.g., having one or more resilientprotrusions engaging a depression), and the like. Also, one or moresealing rings or gaskets (not shown) may be provided to prevent moistureand other contaminant entry into the system. As described above, thepreferred depicted embodiment accommodates connection of the hose 118 oneither side of the chassis 112, according to the user's preference. Inanother preferred aspect, the connectors 120 and/or 124 may be adaptedto swivel or rotate to accommodate user movement, to switch betweenright and left-handed operation.

In the depicted embodiment, the hose assembly 118 includes an optionalpurge valve 264 that provides the operator with an additional burst ofregulated air from the first stage regulator 244 (e.g., about 80-100psi) when needed. The purge valve assembly 264 can include a manuallycontrolled actuator and connection hose 266 that is in fluidcommunication with the first stage regulator 244 in the main bodyportion 112 for introducing additional air into the user mask. Theconnection hose 266 preferably passes through an interior portion of thehose assembly 118 and, more preferably, through an interior portion ofthe perforated inner hose 254. In the depicted embodiment, the hose 266extends through the end 120 of the hose 118, allowing connection to amating connector within the selected connection port 122 or 123. Gas isdelivered from the first stage regulator 244 via the regulated pressurejunction 246.

Another optional feature of the system is to provide a user perceptiblealert when the air pressure drops below a pre-selected pressure level(e.g., below 500 PSI). Such alert may be a visual or audible alarm or,more preferably, a vibrating mechanism that alerts the user withoutdrawing attention to the user. Preferably, the pressure detected issystem or manifold pressure, although employing tank pressure is alsocontemplated. For example, an electronic pressure gauge or electronictransducer 149 (see FIG. 15) may be housed within the manifold 140.

The vibrator 268 or other alarm mechanism may be mounted within theinhalation hose assembly 118, preferably in or near the mask connectionend 124. The vibrator 268 may be electrically coupled to the main powersource within the main body portion 112, e.g., by means of an electricalconnection 270 passing through the inhalation hose assembly 118 and,preferably, within the perforated hose 254. The electrical coupling 270may include a connector 272 which mates with a corresponding connectorallowing connection to a mating connector within the selected connectionport 122 or 123. Alternatively, a dedicated power supply, such as abattery or battery pack, for the vibrator or other alarm 268 is alsocontemplated.

The vibrational unit 268 may employ any of a number of generally knownvibrational elements for producing mechanical vibrations. For example,the vibrational element may employ an electric motor wherein a pivotallymounted weight is mounted at the end of the shaft thereof.Alternatively, other vibrational elements may be utilized to producemechanical vibrations, such as a piezoelectric substance (e.g., quartz,Rochelle salts, or various artificial materials). The application of anelectrical signal to the piezoelectric material induces the material tomechanically vibrate.

It will be recognized that the electrical supply 270 passing through thehose 118 may also be employed to power one or more additional devices inthe mask. For example, the power supply cable 270 may be employed toprovide power to a display device, such as a head up display, indicatorlights, a communication system, and so forth, which may be mounted orintegrated with the user mask.

Referring now to the blower-assisted filter mode of operation, thesnorkel assembly 168 is moved to the open position, e.g., eitherelectronically or manually, as described above. When controlledelectrically, an electronically actuated solenoid valve 274 releasespressurized air from the first stage regulator 244 to close the orifice252 in the snorkel. The snorkel assembly is urged to the open positionvia a mechanical linkage 281 between a cylinder/piston assembly 280 andthe snorkel assembly 168 to open a filtered air valve inlet 276.

In the depicted embodiment, pressurized air from the first stageregulator 244 is in fluid communication with the gas-drivenpiston/cylinder assembly 280, which controls the movement of the snorkelusing the 80 PSI air that comes from the regulated pressure junction246. An electronic sensor controls the flow of gas to thepiston/cylinder assembly 280 when the operator presses the button 196 onthe remote control unit 192. In the depicted embodiment, thepiston/cylinder assembly 280 is fluidically coupled to the regulatedpressure junction 246 via a conduit 282 when the solenoid valve 274 isopened. The piston assembly 280 is thereby extended and retracted tomove the snorkel assembly to the open and closed positions,respectively, by the release of air from the first stage regulator 244.A removable cover 279 may be provided to allow access to the pistonassembly 280 without the need to remove the entire cover 115.

A snorkel position sensor 175 such as a switch, position indicator, orthe like, may be provided to provide an indication of snorkel positionand/or for actuating a prefilter cleaning function as described above.

It will be recognized that other mechanisms for moving the snorkelbetween the open and closed positions. For example, an electric motorand a mechanical linkage for converting rotation of the motor intotranslation of the snorkel may be employed in place of the pistonassembly 280.

However, it will be recognized that the unit 110 may be operated withone or both cylinders 116 removed from the main body 112. Cylindermanifold plugs may be secured over the manifold inlets to seal themanifold intake connections to prevent contaminant entry when thecylinders are not in use. When both cylinders 116 are removed, thesnorkel assembly 170 may be manually moved to the open position in orderto activate the suction source 208 and allow air to flow through thefilter mechanism. It is also contemplated that a dedicated source of gasfor operation of the piston assembly 280, such as a carbon dioxide tankor cartridge or the like be provided for operating the piston assembly280.

In the open position, ambient air 178, e.g., possibly contaminated air,is drawn in by the suction source 208 through the through the inlet 172,optional prefilter 180, and main filter 222 as described above. Airpasses through the filter and into the breathing reservoir 113 of thechassis housing 112. From there, the air flows into the user mask 126,e.g. via the inhalation hose assembly 118, as previously described.

Optionally, a connector 193 is provided for electrically coupling anoptional air sensor module 195 (see FIG. 15) which samples and monitorsthe ambient air for harmful constituents which are unfilterable by themain filter 222. In one such embodiment, if the user is operating theapparatus in the filtered mode and such constituents are detected or theair quality is otherwise determined to be unsafe, the snorkel is movedto the closed position and switched to the self-contained mode ofoperation under preprogrammed control. An audible, visual, or tactualwarning signal may also be provided to the user.

The invention has been described with reference to the preferredembodiments. Obviously, modifications and alterations will occur toothers upon reading and understanding the preceding detaileddescription. It is intended that the invention be construed as includingall such modifications and alterations insofar as they come within thescope of the appended claims or the equivalents thereof.

Having thus described the preferred embodiments, the invention is nowclaimed to be:
 1. A breathing apparatus comprising: a chassis defining apassageway for a breathable gas, said chassis further comprising a firstinlet for receiving breathable gas from a self-contained source ofbreathing gas, a second inlet for receiving ambient air, and an outletfor delivering breathable gas to a user; a suction source coupled tosaid chassis and in fluid communication with said second inlet, saidsuction source for drawing ambient air into said passageway; a mainfilter assembly in fluid communication with the suction source forremoving contaminants from the ambient air; a breathing hose assemblyhaving a first end removably connected to said outlet and a second endopposite the first end, the second end configured to be removablyconnected to an external breathing device; said breathing hose assemblyhaving an inner perforated hose and an outer flexible bag, eachextending from the first end to the second end, the inner perforatedhose arranged longitudinally within the outer flexible bag, wherein theouter flexible bag is inflatable to hold a volume of air for subsequentdelivery to the user; one or more self-contained sources of breathinggas removably attached to said chassis, wherein each of the one or moreself-contained sources of breathing gas is selectively fluidicallycoupled to said first inlet; and an alarm system for providing auser-perceptible alert when a pressure in a connected one of the one ormore self-contained sources of breathing gas falls below a preselectedvalue, said alarm system comprising a somatic communications systemoperatively integrated with said breathing apparatus for tactuallycommunicating with a user by producing a vibrational signal responsiveto a detected low pressure condition; wherein said first end of saidbreathing hose assembly comprises: a vibrating element mounted withinthe second end of said breathing hose assembly for producing tactuallydetectable vibrations; an electrical connector mounted within the firstend of said breathing hose assembly for electrical connection to a powersupply within said chassis; and an electrical conductor passing throughsaid breathing hose assembly for electrically coupling said vibratingelement and said electrical connector.
 2. The breathing apparatus ofclaim 1, wherein the second end of the breathing hose assembly includesa connector element configured for removable attachment to a matingconnection port on the external breathing device.
 3. The breathingapparatus of claim 2, wherein the external breathing device comprises aface mask adapted to be worn over a user's face.
 4. The breathingapparatus of claim 3, further comprising: an outlet valve on said facemask, said outlet valve configured to retain the breathing gas withinthe face mask when pressure within the face mask is below a preselectedthreshold value and to allow gas to escape the face mask when pressurewithin the face mask is greater than or equal to the threshold value. 5.The breathing apparatus of claim 4, wherein the outlet valve isconfigured to maintain a pressure within the face mask which is greaterthan atmospheric pressure.
 6. The breathing apparatus of claim 1,wherein the suction source is mounted within said chassis and the mainfilter assembly is positioned between said second inlet and saidpassageway.
 7. The breathing apparatus of claim 1, further comprising apurge valve connected to the first end of the breathing hose assembly,the purge valve actuable to provide a burst of regulated air from theone or more self-contained sources of breathing gas.
 8. The breathingapparatus of claim 1, wherein said electrical conductor passes withinsaid inner perforated hose.
 9. The breathing apparatus of claim 1,further comprising: a prefilter assembly positioned upstream of the mainfilter for removing contaminants from said ambient air.
 10. Thebreathing apparatus of claim 9, wherein the prefilter includes anexternal filter formed of a woven nylon material.
 11. The breathingapparatus of claim 9, wherein the prefilter assembly includes a meshfiltration medium adapted to filter particles from said ambient air. 12.The breathing apparatus of claim 1, wherein the main filter is selectedfrom a chemical, radiological, or biological filter, or any combinationthereof.
 13. A breathing apparatus comprising: a chassis defining anpassageway for a breathable gas, said chassis further comprising a firstinlet for receiving breathable gas from a self-contained source ofbreathing gas, a second inlet for receiving ambient air, and an outletfor delivering breathable gas to a user; a suction source coupled tosaid chassis and in fluid communication with said second inlet, saidsuction source for drawing ambient air into said passageway; a mainfilter assembly in fluid communication with the suction source forremoving contaminants from the ambient air; a breathing hose assemblyhaving a first end removably connected to said outlet and a second endopposite the first end; said breathing hose assembly having an innerperforated hose extending from the first end of to the second end and anouter flexible bag surrounding the inner perforated hose, the outerflexible bag being inflatable to hold a volume of air for subsequentdelivery to the user, one or more self-contained sources of breathinggas removably attached to said chassis, wherein each of the one or moreself-contained sources of breathing gas is selectively fluidicallycoupled to said first inlet; an alarm system for providing auser-perceptible alert when a pressure in a connected one of the one ormore self-contained sources of breathing system falls below apreselected value, said alarm system comprising somatic communicationssystem operatively integrated with said breathing apparatus fortactually communicating with a user by producing a vibrational signalresponsive to a detected low pressure condition; wherein said first endof said breathing hose assembly comprises: a vibrating element mountedwithin the second end of said breathing hose assembly for producingtactually detectable vibrations; an electrical connector mounted withinthe first end of said breathing hose assembly for electrical connectionto a power supply within said chassis; and an electrical conductorpassing through said breathing hose assembly for electrically couplingsaid vibrating element and said electrical connector.
 14. The breathingapparatus of claim 13, wherein said electrical conductor passes withinsaid inner perforated hose.